valeo compressors - service manual manual... · 2020-03-25 · commercial vehicles air...

SERVICE MANUALValeo TMX

Copyright 2020 Valeo, LTD. All rights reserved.

2

Foreword

This service manual has been elaborated to help service personnel to provide efficient and correct service and maintenance on the TMX model compressor (for HFC-134a and HFO-1234yf) for commercial vehicles air conditioning. This manual includes the operation specifications, procedures for disassembly, reassembly and inspection of the compressor.

The contents of this manual, including illustrations, drawings and specifications were the latest available at the time of printing. Valeo reserves the right to make changes in specifications and procedures at any time without notice.

VALEO INC.

The following warning signs are used in this service manual. These are extremely important to ensure safe operation and to prevent body injuries and property damage. They must be fully understood before starting the air conditioner maintenance.

WARNING! Maintenance must be properly done to avoid serious injury risks.

CAUTION! Improper maintenance can result in injury or property damage.

The following marks are used in this service manual to facilitate correct air conditioner maintenance.

Advice Procedures necessary to ensure the best air conditioner maintenance.

Note Information to optimize the air conditioner maintenance.

WARNINGS

MEANING OF MARK

1. Product description

2. Operation precautions

3. Handling instructions

3.1. Maintenance precautions

3.1.1. Working area

3.1.2. Refrigerant handling

3.2. Compressor handling

3.3. Compressor removal

3.4. Oil Management

3.4.1. Oil return operation

3.4.2. Oil handling

3.4.3. Oil contamination

3.4.4. Oil specification

3.4.5. Oil check

3.5. Running-in operation

3.5.1. Compressor running-in

3.5.2. Magnetic clutch running

3.6. Leak test

3.7. Refrigerant charging

3.8. Installation precautions

3.9. Piping precautions

4. Troubleshooting

4.1. Compressor troubleshooting

4.2. Compressor troubleshooting tree

4.3. A/C cycle diagnosis by gauge pressure

5. Service procedures : Magnetic Clutch

5.1. Exploded view

5.2. Removal

5.3. Inspection

5.4. Installation

6. Service tools

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Contents

P3

P8

P9

P9

P10

P10

P11

P11

P12

P12

P12

P13

P14

P15

P15

P16

P17

P18

P19

P19

P24

P26

P27

P28

P29

P31

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1 - PRODUCT DESCRIPTION - COMPRESSOR

TECHNOLOGY Heavy Duty Fixed Piston Swash Plate Type Compressor

DISPLACEMENT 156.7cc

NUMBER OF CYLINDERS 10 (5 double-headed pistons)

DIRECTION OF ROTATION Clockwise

BORE 30.5 mm (1.2 in)

STROKE 21.4 mm (0.84 in)

SHAFT SEAL Lip seal type

LUBRICATION SYSTEM Splash lubrication

REFRIGERANT R134a or R1234yf

OIL TYPE / AMOUNT * VC100YF PAG OIL / 130 cm3

RATED VOLTAGE 12V DC

* Customer can order Valeo service oil package ➝ Part number: T428727 (1 CASE = 6 x 250 cc can)

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1 - PRODUCT DESCRIPTION - COMPRESSOR

Compressor

1. The compressor must be operated within the green area shown on Table 1.

2. Inclination limit at installation The compressor must be installed on the vehicle within the range shown on Table 2.

Table 2

-21 -2 16 ℃

0.10 0.18 0.38 MPaG0.20 0.28 0.48 MPaA

-6 28 61 ℉

14 25 58 PSIG29 40 69 PSIA

Table 1

Tc

Te

PSIA PSIG ℉ MPaA MPaG ℃

450 435 190 3.10 3.00 88

244 229 140 1.68 1.58 60

160 145 109 1.10 1.00 43

100 85 88 0.69 0.59 31

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1 - PRODUCT DESCRIPTION - PERFORMANCE

The performance data below were measured under the following conditions:● Discharge Pressure: Pd = 1.52 MPaG ● Suction Pressure: Ps = 0.18 MPaG ● Subcooling temperature: SC = 5°C ● Super heat temperature: SH = 10°C

Valeo TMX performance data table (R134a) :

Valeo TMX performance data graph (R134a) :

Nc (r/min) 1000 1500 2000 2500 3000

Vol. Eff. (%) 72.9 73.8 72.2 69.8 66.2

Capacity (kW) 3.3 5.1 6.6 8.0 9.1

Power (kW) 1.4 2.1 2.9 3.7 4.5

COP 2.4 2.4 2.3 2.2 2.0

Capacity

Vol. eff.

Power

COP

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1 - PRODUCT DESCRIPTION - SWASH PLATE SYSTEM

Valeo TMX is a 10 cylinders swash plate type compressors. The cylinders and pistons are arranged axially along the drive shaft. The pistons operate within the cylinders and are driven by a swash plate to perform suction, compression and discharge.

Swash plate system

The drive shaft, which is driven by the engine through the magnetic clutch, is equipped with a swash plate. The drive shaft is supported by two radial bearings and two thrust bearings. The swash plate is rotated by the drive shaft, and moves the pistons back and forth.

The pistons in the cylinders are mounted on the swash plate through hemispherical shoes. Each piston has a compression head at each end. The rotation of the swash plate results in a reciprocating piston movement parallel to the drive shaft. The cylinders, which are arranged at 72° intervals around the drive shaft, are each divided into 2 chambers providing 5 front and 5 rear bores. As each piston performs suction and compression at either end, the compressor operates as a 10 cylinder compressor.

Piston Drive System

Suction

Compression

Suction

Compression

Shoe Piston

Drive shaft Radial bearing Thrust bearing

Swash Plate

Piston

Radial bearing

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2 - OPERATION PRECAUTIONS

Preventive Maintenance

1. During the off season of the air conditioner, operate the compressor for a few minutes once a week.

2. Do not drive through water. Water may damage the magnetic clutch, thus preventing normal operation

3. Do not allow a compressor that has not been used for a long period to become wet.

4. Always charge the A/C system with the specified quantity of refrigerant.

5. Keep the compressor clear of water projection while cleaning the vehicule

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3 - HANDLING INSTRUCTIONS

Maintenance precautions

Working Area

As the components of air conditioners are particularly sensitive to moisture, dirt and rust, always observe the following:● Work indoors whenever possible.● Select a flat ground work area.● Keep the work area clean.● Select a work area with adequate ventilation.

● Keep open flame and inflammables away from the vehicle in which the air conditioner is being installed. (Fire is particularly dangerous during the gas leak inspection following installation).

CAUTION!Refrigerant itself is not harmful but excessive accumulation in a closed area can cause oxygen deficiency.

WARNING!Contact with flame and high temperatures can generate toxic gases.

10


Refrigerant handling

1.Do not misidentify refrigerantsIf an HFC-134a (or HFO-1234yf) air conditioning system is mistakenly charged with another refrigerant, serious problems such as compressor seizure may occur. Therefore, confirm before charging with refrigerant that the type of air conditioning system is an HFC-134a (or HFO-1234yf) system.

2.Do not release refrigerant into the airAlthough HFC-134a (or HFO-1234yf) is not subject to CFC regulations, it can have effect on global warming and so should not be released into the air. When removing refrigerant from the air conditioner system, always use a refrigerant recovery unit made especially for HFC-134a (or HFO-1234yf).

Compressor handling

Do not strike or unnecessarily turn the compressor upside down. If the compressor is knocked over or turned upside down during handling or installation, rotate the armature plate 5 or 6 times by hand to circulate the oil. Otherwise, oil in the cylinder during compressor start-up will cause valve damage and reduce durability.

WARNING!Direct contact with refrigerant can cause frostbite or blindness.Always wear safety glasses and protective gloves.Do not work with refrigerant close to your face.

Safety glasses

Gloves

Do not release refrigerant into the air

Recovery unit

11


Compressor removal

When the compressor is operational1. Perform the oil return operation (p.11).2. Recover the refrigerant from the system using a refrigerant recovery unit.3. Remove the compressor.4. Drain the oil from the compressor and close all open connections immediately.5. Check the oil quantity and the degree of contamination (p.12).

When the compressor is operational1. Recover the refrigerant from the system using a refrigerant recovery unit if the shut-off valves are

removed with the compressor.2. Remove the compressor.3. Drain the oil from the compressor and close all open connections immediately.4. Check the oil quantity and the degree of contamination (p.12).

Oil return operation

Compressor oil mixed with refrigerant is circulating in the air conditioning system. Perform the oil return operation to return this oil to the compressor before removing components from the system.1. Open the doors and windows and operate the

blower motor at maximum speed.2. Operate the vehicle engine at idling at least 20

minutes.

Note: The maximum amount of oil cannot be recovered at higher speeds. This operation also requires a warm ambient temperature.

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Oil quantity inspection

There is no particular need for frequent inspection or replacement of compressor, although it is recommended to check operating refrigerant pressure and oil level at the start of the season. Please replace the refrigerant and restore the system oil, refrigerant charge to factory specifications if:● The AC system is opened for repair or

replacement of any component (e.g. evaporator, condenser or receiver drier)

● Any loss of charge - refrigerant or oil - is detected.

Handling precautions

1. The oil must be free from dust, metal filings, etc.2. Do not mix oils.3. The moisture content must not exceed 1,000

ppm.4. The oil easily absorbs moisture when the

container is open. Therefore always seal the container immediately after use.

Oil contamination

Unlike engine oil, no cleaning agent is added to the compressor oil. Even if the compressor is run for a long period (approximately 1 season), the oil never becomes turbid as long as there is nothing wrong with the compressor or its method of use. Inspect the extracted oil for any of the following. ● Increased opacity of the oil. ● Color change to red. ● Presence of foreign matter, metal filings, etc.

Oil specification

Use only VC100YF PAG OIL Customer can order Valeo service oil package➝ Part number: T428727 (1 CASE = 6 x 250 cc can)

WARNING!When system (oil) contamination is found during compressor replacement, flush the A/C system with a fluid that meets SAE J2670 and replace the dryer (or accumulator).

Do not mix with other oils !

Cap the container immediately

● Foreign substances ● Color change● Metal filings● Opacity

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Oil check

The compressor oil must be checked and adjusted as follows when replace compressor or performance system service:

1. Perform the oil return operation (p.11).

2. Remove the old compressor from the vehicle.

3. Drain the oil through both suction and discharge ports. To drain maximum amount of oil, with both ports facing down, slowly position the compressor at different orientations, then rotate the compressor armature plate 3 ~ 5 turns. Repeat 2 ~ 3 times.

4. Check the oil for contamination.

5. Adjust the oil amount of the new replacement compressor per chart below. In case additional oil need to be added, fill oil through the suction port (see table below).

CAUTION!All of the oil cannot be removed when draining the compressor as some remains as an oil film on the inside of the compressor and the system components. Therefore, refer to the table at left when recharging the compressor with oil. Excess oil adversely affects the cooling capacity and the compressor

Current compressor is

kept

Compressor is replaced

Factory oil

charge

Amount recovered

Charging amount

Amount to remove from

the new compressor

TMX 130

78 or more Same as recovered 52

Under 78 78 39

Current compressor is

kept

Compressor is replaced

Factory oil

charge

Amount recovered

Charging amount

Amount to remove from

the new compressor

TMX 4.6

2.8 or more

Same as recovered 1.8

Under 2.8 2.8 1.4

Unit: cm³ & cc

Unit: ounce

Fill the oil through the suction port

Remove used oil from the discharge and suction ports

CAUTION!The total amount of oil your air conditioning system requires is provided by the system designer or supplier.

14


Running-in operation

Whenever moving parts have been replaced, it is necessary to run-in both the compressor and the magnetic clutch.

Compressor running-in

Reassembled compressors must be run-in after the leak test (p.15).

1. Check that the compressor contains the specified amount of oil (p.13).

2. Interconnect the suction fitting and the discharge fitting with the flexible hose.

3. Connect the two connector ports using a flexible hose

4. Run the compressor at 500r/min for 30 minutes to 60 minutes. This operation may be performed by an electric motor or the engine of an automobile.

5. Replace the oil.

6. Repeat the leak test.

CAUTION!While the compressor is being run-in in step 3 above, check the outside temperature of the front head. If the temperature exceeds 80°C (176°F), stop the running-in operation. Resume the operation when the head has cooled.

Connect the flexible hoses to suction and discharge port

15


Magnetic clutch running-in

1. Install the clutch on the compressor. 2. Install the compressor on the test bench, and

operate the compressor by running the system.3. Maintain the compressor speed at 500 rpm.

Operate the A/C switch through the ON/OFF cycle at least 50 times (“ON” for 10 seconds and “OFF” for 10 seconds)

Leak test

The compressor must be checked for refrigerant leaks after it is repaired. The procedure is as follows. 1. Fill the compressor with refrigerant through the

suction side, raising the refrigerant pressure to at least 0.39 MPaG {5 kgf/cm2 , 56.3 psig}.

2. Check the compressor for leaks using a Helium leak detector.

Low pressure High

pressure

Connect Valve assembly to suction port

ON

OFF

(50 times)

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Refrigerant charging

Countermeasures to avoid charging with the wrong refrigerant have been taken. These include different shaped service valves, different service tool thread sizes, caution stickers and labels.

In order to prevent a liquid charge and greatly increase risks of compressor damage, do not shake or turn the refrigerant bottle upside-down.

Initial Leak Check

Using the leak detector, check the system connections for leaks.

As the system pressure is not yet high, only large leaks can be detected at this time.

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Installation precautions

The new compressor is filled with the specified quantity of compressor oil and nitrogen gas (N2). When mounting the compressor on the vehicle, please follow as below :

1. Loosen the discharge side connector’s cap and gently release nitrogen gas (N2) from the compressor.

2. Turn the magnetic clutch armature plate several times by hand to distribute the oil which has settled in the cylinders.

3. When installing the compressor in service system, the compressor should be installed after adjusting the amount of oil, referring to “oil check” (p.13)

Armature plate

Discharge Port

18


Piping precautions

1. Position the O-Ring against the bulge in the pipe when connecting hoses and pipes.

2. Coat the piping connections and the O-rings with PAG oil.

3. Fit the nuts and unions tightly against the base of the companion pieces, then hand tighten the nut as much as possible. Then tighten to the specified torque.

CAUTION!Always use the specified oil for HFC-134a and HFO-1234yf systems to coat the O-rings.

O-ring positionsCORRECT INCORRECT INCORRECT

O-ring Pipe bulge

Apply oil thoroughly to these areas

Piping connectionCompressor / condenser connection

CORRECT INCORRECT

Piping connection procedureNutUnion

Damage

Gnawing at pipe end

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4 - TROUBLESHOOTING

Compressor troubleshooting

As long as the compressor maintenance is done correctly, there should not be any problem throughout the whole vehicle life, but should it happen, this troubleshooting can help solving the issue.

Below are listed most of the issues you may encounter while the A/C is ON. Please refer to the compressor troubleshooting tree to localize the malfunction symptom, then look at the table (p.24-25) for the appropriate counter measure.

Most of the malfunction symptoms can be classified in the following categories: 1. Insufficient cooling capacity 2. Abnormal noise3. Smoke

In case of insufficient cooling capacity, we recommend that you prepare a gauge manifold to measure the pressure of both discharge and suction sides (for a detailed diagnosis by gauge pressure, p.24-25).

Compressor troubleshooting tree

1. Insufficient cooling capacity A. Compressor is not running

B. Compressor is running

C. Compressor runs intermittently

A. Abnormal noise from compressor

B. Abnormal noise from magnetic clutch

C. Belt slipping noise

A. Magnetic clutch friction surface slipping

B. Magnetic clutch belt slipping

C. Smoke from magnetic clutch

D. Smoke from compressor

3. Smoke

2. Abnormal noise

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4 - TROUBLESHOOTING

1. Insufficient cooling capacity

A. Compressor is not running(no cool blow coming out)

Replace the compressor

Fix the refrigerant leakage then fill with refrigerant until reaching the right amount

Replace the lead wire if it is defective

Replace the magnetic clutch

Replace magnetic clutch

Check the voltage of battery

Service system and replace the compressor

Replace compressor if it is locked

Replace compressor or magnetic clutch

Compressor internal damage

Refrigerant shortage

Lead wire short circuit or wiring connector not seated properly

Magnetic clutch damage

Magnetic clutch air gap too wide

Low magnetic clutch voltage

Thermal fuse activated by high heat

Belt slipping

Compressor internal part damage or magnetic clutch damage

Replace magnetic clutchBolt drop off / Armature drop off

Magnetic clutch slips when turning on the A/C switch

Low pressure cut switch operates

The magnetic clutch slips or does not engage when the compressor runs

The magnetic clutch engages but the armature does not rotate

Belt run off the pulley

Center bolt is loose / Center bolt is missing

Issue Symptom Potential cause Counter measure

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4 - TROUBLESHOOTING

Reduce the refrigerant charge until reaching the right amount

Replace the condenser after making sure it is defective

Replace the magnetic clutch after making sure it is defective

Replace the thermostatic switch after making sure it is defective

Excess of refrigerant

Condenser fan failure

Loose connection of the magnetic clutch electrical circuit

Defective thermostatic switch

Both discharge and suction pressures are high

The magnetic clutch slips or does not engage when the compressor is running

The magnetic clutch does not engage

C. Compressor runs intermittently (cool blow comes out irregularly)


Replace compressor

Fix the refrigerant leakage then fill with refrigerant until reaching the right amount

Check the voltage of the battery or replace the magnetic clutch

Replace the magnetic clutch if it is clutch defect

Belt tension adjustment

Replace the thermostatic switch after making sure it is defective

Defective compressor

Refrigerant shortage

Magnetic clutch friction surface slipping

Loose connection of the magnetic clutch with electrical circuit

Magnetic clutch belt slipping

Defective thermostatic switch

Compressor is running abnormally

No difference of temperature between discharge side and suction side (see p.24-25)

The magnetic clutch slips or does not engage when the compressor is running

Belt slipping

The magnetic clutch does not engage

B. Compressor is running (no cool blow coming out)

1. Insufficient cooling capacity

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2. Abnormal noise

Increase tightening torque of the loose bolts

Mount compressor correctly


Compressor installation bolt is loose

Wide gap at the attaching portion between the compressor and the engine mounting points

Compressor body internal component damage

Abnormal vibration after turning on the A/C switch

Abnormal noise from the compressor body

A. Abnormal noise from the compressor


Replace the magnetic clutch

Replace magnetic clutch

Check the voltage of battery or replace magnetic clutch

Magnetic clutch damage

Air gap too wide

Magnetic clutch friction, slippery surface

The magnetic clutch has a backlash and slips

Strange noise when the magnetic clutch engages

Armature slips does not engage when the compressor is running

B. Abnormal noise from the magnetic clutch

Replace the compressor if locked. Adjust the belt tension if the belt is loose

Belt slippingArmature does not rotate when magnetic clutch engages

C. Belt slipping noise

4 - TROUBLESHOOTING

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4 - TROUBLESHOOTING

3. Smoke


Adjust air gap or replace magnetic clutch

Check the voltage of battery

Clean friction surface or replace magnetic clutch

Magnetic clutch air gap too wide

Low magnetic clutch voltage

Magnetic clutch friction, greasy surface

The magnetic clutch slips / does not engage when the compressor is running

A. Magnetic clutch friction surface slipping

Adjust the compressor installation position

Clean or replace the belt

Adjust belt tension

Belt alignment is not correct

Magnetic clutch belt is greasy

Magnetic clutch belt tension is loose

The magnetic clutch slips / does not engage when the compressor is running

B. Magnetic clutch belt slipping

Replace the magnetic clutchCoil open or shortedThe magnetic clutch does

not engage

C. Smoke from the magnetic clutch

Fix the refrigerant leakage then fill with refrigerant until having the right amount

Reduce the refrigerant charge until reaching the right amount

Refrigerant leaking, uncoupled piping or piping burst

Refrigerant blowing from the high pressure relief valve due to excess of refrigerant

Refrigerant / oil is blowing out

D. Smoke from the compressor

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4 - TROUBLESHOOTING

A/C cycle diagnosis by gauge pressure

Following is a diagnosis procedure to connect gauge manifold to A/C cycle, measure suction and discharge pressures and analyze the defects of the cycle.

Operation conditions of the A/C cycle for pressure measuring:1. Ambient temperature: 30 - 35 °C 2. Engine speed: 1,500 rpm 3. A/C switch: ON4. Blower speed: high 5. Temperature control: full cold

Gauge pressure indication Cause Confirmation method Action to take

Pressure is normal

A/C cycle operates normally. If there is any defect (poor cooling performance), there shall be another cause.● Discharge pressure: around 0.9 - 1.6 MPaG (10 - 17 kgf/cm²) ● Suction pressure: around 0.03 - 0.10 MPaG (1.3 - 2.0 kgf/cm²)

Both discharge and suction pressures are low

Refrigerant shortage Connect gauge manifold to cycle

Recover refrigerant, then refill with the right amount of refrigerant

Receiver dryer is clogged

Temperature difference between inlet and outlet pipes happens. Dryer is covered with frost

Replace parts

Expansion valve is clogged

Expansion valve was covered with frost or dust

Clean or replace part(Tightening torque = 7.8~9.8N.m)

Enclosure leakage from the expansion valve temperature sensing tube. (Expansion valve operates to close the valve opening)

Outlet side of the expansion valve is not cooling. (Low side of gauge indicates vacuum)

Replace part

Temperature sensing device at outlet air is defective

Evaporator becomes frozen up

Adjust or replace the part

Refrigerant piping is clogged or crashed

If any part between the dryer and the compressor is clogged or crashed, the low side pressure becomes vacuum

Adjust or replace the part

25

4 - TROUBLESHOOTING

Gauge pressure indication Cause Confirmation method Action to take

Both discharge and suction pressures are high

Excess of refrigerant Connect gauge manifold to cycle

Recover refrigerant, then refill with the right amount of refrigerant

Condenser cooling malfunction

Condenser becomes muddy and fins are clogged and collapsed. Defect of cooling fan rotation. Malfunction of fan motor for condenser

Clean up, hand repair of fin and replacement

Misaligned Expansion valve or thermal sensing tube of the Expansion valve is not fit on regularly. (Excess opening of the Expansion valve)

Defective refrigerant flow control, the thermal sensing tube is not closely in contact with the evaporator pipe

Adjustment or replacement

Air mixed in refrigeration cycle

Just after compressor stops, discharge pressure will come down immediately to 0.19 - 0.29 MPaG (3 - 4 kgf/cm²)

Evacuate air from cycle, the charge with the adequate amount of refrigerant

Discharge pressure is high and suction pressure is low

Refrigerant cycle is clogged between compressor and condenser

Appreciable temperature difference at the clogged location

Clean up inside the cycle or replace the part

Discharge pressure is low and suction pressure is high

Defect of the compressor valve or gasket

Discharge and suction pressures balance immediately after the compressor stops. (Defective compression of compressor)


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6 - SERVICE PROCEDURE - MAGNETIC CLUTCH

1. Center bolt2. Armature plate 3. Adjusting shim4. Snap ring5. Pulley assembly 6. Coil Screw7. Field coil8. Compressor body

Exploded view of Magnetic Clutch

1

2

3

4

5

6

7

8

Tightening torques Air Gap(between Armature plate and

Pulley) Center Bolt Coil Screw

14.5~15.5 N-m(10.7~11.4 ft lbs)

3.9~5.9 N-m(2.9~4.4 ft lbs)

0.3~0.6 mm(0.012~0.024 in)

Clutch Assembly Specifications

27


Magnetic Clutch

Removal

● Step 1: Remove the center bolt using a drive plate holder (p.31) to prevent armature plate from rotation.

● Step 2: Remove the armature plate by hand or using a M8 screw if necessary.

● Step 3: Remove the snap ring using external snap ring pliers.

● Step 4: Position the center pulley puller at the end of the driveshaft.

● Step 5: Attach a suitable pulley puller to the pulley. Hook the puller claws to the edge of the pulley.

● Step 6: Tighten the pulley puller bolt to remove the pulley.

28


Magnetic Clutch

Removal

● Step 7: Remove the field coil lead wire bushing using a flat screwdriver (p.31).

● Step 8: Remove the three field coil/compressor screws. Then remove the field coil.

Inspection

1. If the contact surface has been damaged by excessive heat, the armature plate and pulley must be replaced.

2. Check the appearance of the pulley assembly. If the pulley grooves show excessive wear due to slippage, both the pulley and armature plate must be replaced, The contact surfaces of the pulley assembly must be cleaned with a suitable solvent before reinstallation.

3. Check the field coil for a loose connector or cracked insulation.

CAUTION!Do not hold the field coil by the harness

Armature plate

Pulley assembly Field coil

29


Magnetic Clutch

Installation

● Step 1: Install the field coil on the compressor (with the harness on top) and tighten the mounting screws to the specified torque (p.26).

● Step 2: Carefully place the the wire harness bushing.

● Step 3: Install the pulley assembly using a pulley installer (p.31) and an hand press.

● Step 4: Install the snap ring (beveled edge up) using external snap ring pliers.

CAUTION!Use only a press to install the pulley assembly. Do not use a hammer. An hammer will damage or deform the pulley

30


Magnetic Clutch

Installation

● Step 5: Install the armature plate on the driveshaft together with the original shims. Press the armature assembly down by hand.

● Step 6: Install the center bolt and tighten the bolt to the specified torque (p.26) using a drive plate holder (p.31).

● Step 7: Use a feeler gage to check clutch air gap (p.31). If necessary adjust the air gap using shims (p.26).

● Step 8: Run-in the clutch (p.15)

CAUTION!After tightening the center bolt, check that the pulley rotates smoothly.

31

7 - SERVICE TOOLS

Special service tools required for clutch assembly / disassembly

● Armature plate holder → To fix the drive plate● Lead wire bushing remover → To remove lead wire● Pulley installer → To install pulley● Pulley puller + Center pulley puller → To remove pulley

Other regular service tools needed:

● M8 screw → To remove armature● Filler gauge → To check air gap● Flat screwdriver → To remove wire harness

Armature plate holder

Lead wire bushing remover Pulley installer Pulley puller

Valeo TMX compressor

TMX compressor benefits

Asia

Address: 39 Sendai, Kumagaya-shi, Saitama-ken 360-0193, Japan Tel: +81 (0) 48 539 3800 Mail: [email protected]

China

Address: No.2677 Shiji Avenue, Eco. & Tec. Dvt Zone 130031 Changchun, Jilin PRC ChinaTel: +86 (0) 431 8499 2025Mail: [email protected]

Europe, Middle East & Africa

Address: ul. Bestwinska, 43-500 Czechowice,Poland Tel: +48 (0) 3273 79 775 Mail: valeo.compressors.europe. [email protected]

Americas

Address: 480 Wrangler Drive, Suite 200, Coppell, TX, United StatesTel: +1 972 426 6639 Mail: [email protected]

India

Address: B300 A, 124-A, INDOSPACE INDUSTRIAL PARK, Vallam Village, Sriperumbudur Taluk, Kanchipuram District - 602 105, Tamil Nadu, IndiaTel: +91 44 6710 4200 Mail:[email protected]

● Staggering value through innovation

● Reduced noise and vibration

● Improved field serviceability

● Compact & robust design

● Lower fuel consumption

● Enhanced performance

● Higher cooling capacity

● Integration flexibility

● High reliability

Cust

omer

satis

fact

ion

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valeo compressors - service manual manual... · 2020-03-25 · commercial vehicles air...

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